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Unread 07-29-2016, 08:16 PM   #1
Gone Wild
 
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Default Repair Ideas Needed

Picked up a 2006 DS at a good price the other day...today started the pull apart and inspect.

I found some decent corrosion on the drivers side battery tray and need some ideas on how to fix that correctly? See picture below - just grind out that spot and then rivet in some 1/8" Angle from Lowe's? Also what is that tab in the front for? Its on both sides but doesn't seem to have anything attached to it. Picture below is after a few gallons of baking soda/water mixture - probably needs just a few more.



Second issue is the opening on to the batteries - driver's rear corner is cracked. I noticed that the seat (aftermarket see below, but comfy) doesn't look like it goes back far enough on the lip and barley has any support holding it up...ideas? Also it looks like the controller is right behind this area - is that where it's supposed to be from factory?
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File Type: jpg crack.jpg (187.0 KB, 0 views)
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Unread 07-30-2016, 07:36 AM   #2
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Default Re: Repair Ideas Needed

I'm not a body man, but I would try and put a fiberglass patch on the underside and then apply another patch to the top side. Some one else might have a better idea.
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Unread 07-30-2016, 10:59 AM   #3
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Default Re: Repair Ideas Needed

jbsmith05,

What kind of condition are the batteries in? There is a bolt-on conversion kit to put six 8 volt batteries in that cart as opposed to the four 12s. It will give you much better run time and longer battery life than the 12s. It's intended to bolt onto the factory battery racks, which look to me to be nearly destroyed in the corners. However, I think it would be much easier to make a couple of steel brackets to hold the new racks in place, rather than put some aluminum there with rivets to hold the 12 volt batteries. Over time I think the rivets would deteriorate and the racks would fall apart.
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Unread 07-30-2016, 12:58 PM   #4
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Default Re: Repair Ideas Needed

The bats are only a year old and are in good condition. Not worth the expense to switch out. Only bad spot is that one corner after inspection today in sunlight. I think can fab something.

As for the body crack. I think k the fiberglass is the way to go.
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Unread 07-30-2016, 08:26 PM   #5
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Default Re: Repair Ideas Needed

I gotcha. I'd run them til they needed to be replaced. It will pay off in the long run to convert it, but I agree it's best to wait until it's a must.
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Unread 07-31-2016, 01:21 PM   #6
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Default Re: Repair Ideas Needed

well I'm not sure if this is going to hold but for the battery tray fix I used some 1/8" angle aluminum, JB Weld and a bolt. I'm thinking about putting a bolt / rivet down through the flat where the clamps are.

So far after sitting for about 20 hours it seems solid....guess time will tell if a batt drops out!!

Fiberglass patch seems to be pretty strong and holding well to...needs a few more layers and some sanding/finishing but I think that will work out well.
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Unread 07-31-2016, 04:45 PM   #7
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Default Re: Repair Ideas Needed

I would get a small piece of rubber to put between the battery and the head of the carriage bolt, I made that same repair on a cart one time and the carriage bolt head rubbed on the battery and wore a hole in the battery casing. Luckily the batts were old and needing replacement anyway, when the owner got new batts we put a strip of roofing rubber in there he has not had any problems since.
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Unread 07-31-2016, 04:50 PM   #8
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Default Re: Repair Ideas Needed

Quote:
Originally Posted by Frizbgolf View Post
I would get a small piece of rubber to put between the battery and the head of the carriage bolt, I made that same repair on a cart one time and the carriage bolt head rubbed on the battery and wore a hole in the battery casing. Luckily the batts were old and needing replacement anyway, when the owner got new batts we put a strip of roofing rubber in there he has not had any problems since.
yeah I was going to do something like that. probably also if I rivet the old and new AL angle together.

By the way - what is roofing rubber?
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Unread 08-01-2016, 08:51 AM   #9
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Default Re: Repair Ideas Needed

Quote:
Originally Posted by TahoeDawgZ71 View Post
jbsmith05,

What kind of condition are the batteries in? There is a bolt-on conversion kit to put six 8 volt batteries in that cart as opposed to the four 12s. It will give you much better run time and longer battery life than the 12s. It's intended to bolt onto the factory battery racks, which look to me to be nearly destroyed in the corners. However, I think it would be much easier to make a couple of steel brackets to hold the new racks in place, rather than put some aluminum there with rivets to hold the 12 volt batteries. Over time I think the rivets would deteriorate and the racks would fall apart.
Do you have a link or some documentation for this bolt on conversion to 6 batts? While not doing it right now - It has me thinking as I was working on the cart.

By the way...I did seem to get something fab'd up and bolted to where it's holding the batts in place...so far! :)
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Unread 08-01-2016, 11:29 AM   #10
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Default Re: Repair Ideas Needed

Quote:
Originally Posted by jbsmith05 View Post
Do you have a link or some documentation for this bolt on conversion to 6 batts? While not doing it right now - It has me thinking as I was working on the cart.

By the way...I did seem to get something fab'd up and bolted to where it's holding the batts in place...so far! :)
I have a picture. Don't have any instructions handy.
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